Universal barrier system panels

ABSTRACT

A universal barrier system includes universal barrier components that may be assembled together to shield floors and walls from moisture and provide a thermal break in an operational area of the universal barrier component. A lap zone of the universal barrier component may allow universal barrier components to be assembled and installed to protect floors, walls, ceilings, footings and the like from moisture and heat gain or loss by minimizing the need for tapes and other joining methods. The universal barrier system may also act as a sound deadening material. The operational area and lap zone of the universal barrier component may be disposed on a vapor block layer to provide some rigidity. The operational area of the universal barrier component may include a thermal break disposed upon the vapor block layer. The thermal break may include an outer protective layer. In addition, universal barrier tape and universal barrier edging may be provided to couple adjoining universal barrier components.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation in part of U.S. patent applicationSer. No. 12/039,438, filed Feb. 28, 2008, which claims the benefit ofU.S. Provisional Patent Application No. 60/895,932 filed Mar. 20, 2007the disclosures of which are incorporated herein by reference. Thisapplication also claims the benefit of U.S. Provisional PatentApplication No. 61/802,611 filed Mar. 16, 2013 the contents of which arehereby incorporated by reference.

TECHNICAL FIELD

This description relates generally to building construction and morespecifically, to thermal breaks and moisture or vapor barriers.

BACKGROUND

In building construction, a great amount of effort is typically expendedin shielding the building interior and its inhabitants from theelements. In particular, a building typically shields its occupants frommoisture, heat and cold. In addition, moisture can be harmful to thebuilding structure itself. The roof, walls and floor of a buildingtypically include a number of components provided to resist theelements. For example, a wall may include exterior shingles, sheeting,insulation, a frame and interior plaster. A floor may include afoundation footing, a concrete slab and a reinforcing mesh.

Existing structural components have traditionally provided adequateshielding when they were developed. However, as times have changed,energy costs have risen, which tend to make improved insulation moreimportant. Also, as time goes on, builders typically seek to improve thequality and cost effectiveness of their construction methods. An areathat could be improved, is providing cost effective moisture and vaporbarriers that may tend to more effectively protect a building and itsoccupants. In particular, insulating materials that may utilize chemicalcompositions that are energy efficient may be desirable.

SUMMARY

The following presents a simplified summary of the disclosure in orderto provide a basic understanding to the reader. This summary is not anextensive overview of the disclosure and it does not identifykey/critical elements of the invention or delineate the scope of theinvention. Its sole purpose is to present some concepts disclosed hereinin a simplified form as a prelude to the more detailed description thatis presented later.

The present example provides a universal barrier system that tends toreduce the vapor and moisture intrusion into a structure. The universalbarrier system may utilize a unique insulating material made frompolyurethane polymers that include a microsphere (hollow glass bubble)material to improve their insulating properties. The universal barriersystem may also provide a thermal break for improved insulation. Theuniversal barrier system includes universal barrier components that maybe assembled together to shield floors and walls from moisture andprovide a thermal break in an operational area of the universal barriercomponent. A lap zone of the universal barrier component may allowuniversal barrier components to be assembled and installed to protectwalls, floors, footings and the like from moisture and from heat gain orloss. The operational area and lap zone of the universal barriercomponent may be disposed on a vapor block layer to provide somerigidity. The operational area of the universal barrier component mayinclude a thermal break disposed upon the vapor block layer. The thermalbreak may include an outer protective layer. The universal barriercomponents may be disposed upon a roll during manufacturing, for easytransport and installation. In addition, tape may be provided to coupleadjoining universal barrier component panels.

Many of the attendant features will be more readily appreciated as thesame becomes better understood by reference to the following detaileddescription considered in connection with the accompanying drawings.

DESCRIPTION OF THE DRAWINGS

The present description will be better understood from the followingdetailed description read in light of the accompanying drawings,wherein:

FIG. 1 is a plan view of a universal barrier component.

FIG. 2 is a profile view of the universal barrier component of FIG. 1.

FIG. 3 is a plan view and a profile view of a universal barriercomponent bonding tape.

FIG. 4 is a plan view and a profile view of a universal barriercomponent edging material.

FIG. 5 is a flow diagram showing a method of producing a universalbarrier component on rolls.

FIG. 6 is a flow diagram showing a method of producing a thermal breakmaterial

FIG. 7 is a diagram showing a method of laminating materials to create auniversal barrier component.

FIG. 8 is a perspective view of a rigid universal barrier componentpanel.

FIG. 9 is a view of a universal barrier vacuum insulated panel system.

FIG. 10 is a section view where universal barrier system is used with aconcrete slab floor.

FIG. 11 is a plan view of use of a universal barrier system is used witha concrete slab floor.

FIG. 12 is a section view of a house wall.

Like reference numerals are used to designate like parts in theaccompanying drawings.

DETAILED DESCRIPTION

The detailed description provided below in connection with the appendeddrawings is intended as a description of the present examples and is notintended to represent the only forms in which the present example may beconstructed or utilized. The description sets forth the functions of theexample and the sequence of steps for constructing and operating theexample. However, the same or equivalent functions and sequences may beaccomplished by different examples.

The assemblage of components described below may be advantageouslyassembled in a variety of applications, or may be termed universal as aset of a few standardized components may be universally applied in avariety of applications. The various components advantageously utilize aseries of thin sheets on a roll laminated together to provide desiredproperties that are light weight, flexible, formable, shapeable, havehigh performance resistance to thermal, vapor, moisture and soundmigration, and come in easily transportable in rolls.

The examples below describe a vapor or moisture barrier system that mayinclude a thermal break. The system advantageously utilizes convenientlyformed, and typically rolled components whose shape and constructionfacilitate transportation and application at the job site. Although thepresent examples are described and illustrated herein as beingimplemented in a building construction system, the system described isprovided as an example and not a limitation. As those skilled in the artwill appreciate, the present examples are suitable for application in avariety of different types of thermal and moisture barrier systems. Forexample the various components may be utilized in walls, roofs,ceilings, around windows and doors, under concrete slabs, stem walls,and the like. Because of the wide applicability of these insulating andmoisture blocking components they may be said to create a universalbarrier system or a building barrier system when assembled or otherwiseintegrated into building construction.

Various standards are named herein. Such references are used to indicatethat the examples described herein are in compliance with the variousstandards mentioned at the time of this writing. As used herein ACI302-1R refers to American Concrete Institute (“ACI”)'s standard Guidefor Concrete Floor and Slab Construction. American Society for TestingMaterials (“ASTM”) standard ASTM D-1709 refers to the standard for“Standard Test Methods for Impact Resistance of Plastic Film by theFree-Falling Dart Method”, ASTME E-154 refers to the standard for“Standard Test Methods for Water Vapor Retarders Used in Contact withEarth Under Concrete Slabs, on Walls, or as Ground Cover”, ASTME 1643-98refers to the standard for “Standard Practice for Vapor Barriers”, ASTME1745-97 refers to the standard for “Plastic Vapor Barriers” and ASTME1993-98 refers to the standard for “Bituminous Vapor Barriers”

As an overview, the present example provides a universal barrier systemthat tends to reduce the vapor and moisture intrusion into a structure.The universal barrier system may also provide a thermal break forimproved insulation and noise attenuation. The universal barrier systemmay be disposed under a floor, or slab, and may also be assembled toinsulate building footings. In walls, the universal barrier system maybe assembled to limit moisture intrusion and provide insulation.

The universal barrier system includes universal barrier components thatmay be assembled together to shield floors and walls from moisture andprovide a thermal break in an operational area of the universal barriercomponent. An operational area is a region that includes a layeredstructure of a base component, insulation, and an optional protectivelayer that provides insulation/vapor blocking properties. The universalbarrier system may also act as a sound deadening material. A lap zone ofthe universal barrier component may allow universal barrier componentsto be assembled and installed to protect walls, floors, footings and thelike from vapor, moisture, and from heat gain or loss by minimizing theneed for tapes and other joining methods. The operational area and lapzone of the universal barrier component may be disposed on a vapor blocklayer to provide some rigidity. The operational area of the universalbarrier component may include a thermal break disposed upon the vaporblock layer. The thermal break may include an outer protective layer. Inaddition, tape may be provided to couple adjoining universal barriercomponents.

The universal barrier components may be disposed upon a roll duringmanufacturing for easy transport and installation. Disposition andlamination may be advantageously accomplished simultaneously by a hybridprocess of disposing a thermal break between the outer protective layerand vapor block layer. A typical vapor block layer may be provided bypolyethylene, Polyolefin (Copolymer of Ethylene and Hexene: (CH2-CH2)n),Polyolefin EVOH (Ethylene Vinyl Alcohol Copolymer Copolymer of Ethyleneand Octene-1: (CH2-CH2)n) such as found in the exemplary VaporBlock™material produced by Raven Industries of Sioux Falls, S. Dak. or itsequivalent. These concepts will be described in detail in the followingparagraphs.

FIG. 1 is a plan view of a universal barrier component 100. Theuniversal barrier component 100 may be a part of a universal barriersystem that may include other thermal breaking components and ormoisture barriers and vapor barriers. In general the universal barriercomponent is substantially a flexible laminated structure configured sothat it may easily be transported to a jobsite and cut and joined byworkers as needed to conform with the structure in which it is beingdisposed. The components may easily joined without protruding seamswhere adjoining materials are lapped together. A typical universalbarrier system may include the universal barrier component, insulatingedging, and seaming tapes applied as needed in a given application, suchas the construction of a building.

In particular, a universal barrier system for a floor or concrete slabmay include multiple universal barrier components 100 coupled togetherto provide a thermal break and/or a moisture barrier under concrete orother flooring materials. Further, universal barrier systems may includethe universal barrier component 100 coupled together and forminginsulated footings and the like. Such a flooring system utilizinguniversal barrier components 100 may also extend to, and be coupled to,building walls that may or may not include the universal barriercomponents 100, and in a similar manner to roof components to form abuilding envelope providing thermal breaks and a moisture vapor barrier.

Universal barrier component 100 includes an operational area 102 and alap zone 104. A typical overall width for a universal barrier component100 is 54 inches, with a six inch wide lap zone 104 for overlap and a 48inch wide operational area 102. In alternative examples, other widths oflap zone and operational area may be utilized. The universal barriercomponent 100 may be fabricated in any suitable length (“L”). Theuniversal barrier component 100 is somewhat flexible and easy to workwith. Also, the universal barrier system component 100 may be suppliedin convenient lengths on a roll or alternatively in sheets cut to agiven length. The operational area 102 and lap zone 104 of the universalbarrier component 100 are typically disposed on a common base material106.

The operational area 102 typically includes a vapor blocking basematerial or substrate 106, a thermal break, or insulation material 108,and a facing material 110 over the thermal break. This portion of theuniversal barrier component provides insulation properties in theoverall assembly. The operational area 102 typically includes a thermalbreak 108 disposed on the base material 106. The operational area mayalso include an outer layer of facing material 110 disposed over thethermal break 108. The outer layer is typically a lighter weightmaterial suitable for protecting the material making up the thermalbreak 108.

The lap zone 104 allows substantially flush seams to be created whenjoining universal barrier components into larger assemblies, as thisarea is thinned because of the absence of the insulating material, andtypically just being an extension of the base component past theinsulation and outer protective area. The lap zone allows the firstuniversal barrier component to be assembled to the operational area of asecond universal barrier component with their operational areassubstantially joined. The lap zone 104 may include a self-adhesivematerial 112 disposed on the base material 106, for coupling theuniversal barrier component 100 to the adjoining operational area of anadjoining universal barrier component of a plurality of universalbarrier components. The adhesive may be any conventional type suitablefor use in the disclosed configuration. The adhesive may be protected bya non-sticking backing material that may be peeled away to couple theuniversal barrier component to an adjoining universal barrier component,universal barrier insulated edging, or other structural component.Alternatively the lap zones may be supplied without adhesive and joinedby tape, although this creates the need for an additional component whenputting the barrier components together in a construction project.

FIG. 2 is a profile view of the universal barrier component 100 ofFIG. 1. The profile in the operational area 102 and the lap zone 104 areshown. The somewhat flexible vapor block layer forms a base component orbase material 106 of the universal barrier component 100, which is acommon base material 106 for both the lap zone 104 and operational areas102. The vapor block layer 106 may be made of a polyethylene film madeof virgin resin of a high tensile strength typically exceeding ASTME-1745 class A, B and C requirements or its equivalent.

An exemplary base material 106 would be the polyethylene filmmanufactured by Raven Industries of Sioux Falls, S. Dak. and sold underthe trade name VaporBlock™ 10 which may be of 10 mils in thickness. Asuitable tensile strength for this material would be as defined in ASTMEE-154 Section 9 and having a strength of 52 pounds per inches for newmaterial and 55 pounds per inch after soaking. Puncture resistance wouldbe as defined ASTM D-1709 Method B and would be 2600 grams. A typicaluse of that temperature range would be −70° F. to 180° F., and a typicalnew material permanence for a vapor block layer would be 0.036 Perms. Inalternative examples, different thicknesses of the rigid vapor blocklayer 106 may be used, for example, 6 and 15 mils, or the like.

The base material 106 is a vapor block layer that typically impedes thetransmission of water vapor from traveling upward through a concreteslab-on-grade or through a concrete or masonry wall. Installation of thevapor block layer 106 should be such that it is not punctured topreserve its properties. Thus, adhesive joining as previously describedmay be advantageous.

Thermal break 108 typically includes an insulating material such as longchain polymers disposed over the base material 106 in the operationalarea 102. The thermal break may vary in thickness but may typicallyrange from 5 mils to 50 mils, depending on the insulation material andthe degree of insulation desired. Typical thermal break materials mayinclude long chain polymers, such as polyethylene, polystyrene,polypropylene, polyvinyl chloride, for example, that include foams andsilicones. These materials tend to improve the thermal performance ofthe universal barrier components in various configurations.

In a particular example, long chain polymers of polystyrene that aredisposed on the base layer by a hybridized process having two stagesincluding extrusion and blowing may produce a thermal break materialthat is closed cell in construction, easily disposed and flexible(unlike the typically rigid white polystyrene building panels typicallyfound in the building industry). The thickness of polystyrene closedcell material may vary but may typically range from 5 mils to 50 mils,depending on the degree of insulation desired.

In a further alternative example of a thermal break, a urethane, orequivalent material having insulating bubbles or microspheres speciallycompounded as described herein may be utilized as a thermal breakmaterial. This urethane material introduces insulating voids is flexibleand may be easily applied on the base material. The thickness ofurethane with micro spheres may vary but may typically range from 5 milsto 50 mils, depending on the degree of insulation desired.

The outer protective layer 110 typically includes a facing material suchas aluminum foil (or its black body equivalent) or a polyethylene film(or its equivalent) to protect the thermal break from damage and toincrease resistance to moisture. The aluminum foil would typicallyinclude high purity aluminum for reflectivity. Aluminum foil of thistype would typically range from 3 mils to 10 mils, depending on thedegree of reflection or conduction desired. The outer protective layerprotects the material making up the thermal break 108 from moisture andabrasion. The use of high purity aluminum (97% or higher) typicallyimproves the overall thermal performance of the thermal breakingproperties of the universal barrier component for certain applications.

An outer protective layer of polyethylene film may alternatively beutilized. It is typically the same material as described above for thebase material 106, but usually thinner. The thickness of polyethylenefilm material may vary but may typically range from 3 mils to 40 mils,depending on the degree of insulation desired. The outer protectivelayer 110 may also be sealed against the base component 106 around theedges of the operational area 201 and 202 to provide additionalprotection to the thermal break material 108 that it is covering.

FIG. 3 is a plan view and a profile view of a universal barriercomponent bonding tape, or equivalently universal barrier tape. Auniversal barrier bonding tape, or alternatively universal barrier tape,may be used to join universal barrier component 100 to other universalbarrier components (in particular universal barrier components lackingadhesive in the lap zone) or to structural features to which theuniversal barrier components are being applied. Bonding tapes maytypically be up to 12 inches wide and may be made of a “VaporBlock 10”™material and a conventional adhesive. The bonding tapes typicallyprovide 6 inches of lap as specified in ACI 302-1 R. The tape istypically supplied on rolls. However it may equivalently be supplied instrips, or precut lengths. Alternatively the bonding tape may be doublesided with adhesive on both surfaces.

The universal barrier tape material is of the same vapor barrierspecified in the base component or material. This exemplary 12″ tape isdirected at addressing the short width of material at the “operationalarea” and “lap zone”. This 12″ element or vapor barrier tape allows for6″ of overlap (lap zone) on the short ends of the rolled material toprovide the 6″ lap as specified in ACI 302-1R when executing a joint onthe short width of the material. The universal barrier tape provides asolution for the secondary and tertiary functions of vapor and moisturemigration on the widths of the roll material. This element of UniversalBarrier tape also serves to allow custom fabrication (cutting andshaping of the “operational area”) for conformation around room entries,support points (columns and pillars) utility and drain points withoutloss of continuity of the vapor and moisture migration material in the6″ overlap on either side of the fabricated cut or seam of theoperational area to provide a complete system of continuity as specifiedin ACI 302-1R compliance.

FIG. 4 is a plan view and a profile view of a universal barriercomponent edging material, or universal edging material. It is similarin construction to the universal barrier component (100 of FIG. 1),however, its operational area 102 tends to be narrower in width.Insulated universal barrier edgings of the same insulting materials 102as previously described and, may be provided in typical widths of 12 to14 inches to join universal barrier components to each other and to thestructure being insulated. The insulated edgings typically provideinsulating materials from 6 to 8 inches wide and have a lap zonetypically 6 inches wide, covered with the previously described adhesivein compliance with ACI 302-1R. The configuration is similar to that ofthe previously described universal barrier component 100, but withsubstantially narrower widths of operational areas.

The universal edging material is a version of the exemplary 12″ taperoll material where 6″ of the thermal insulation material is disposed on½ of the 12″ width of the tape leaving the remaining 6″ of the vaporbarrier material as the “lap zone”. This universal edging material isdirected at providing a solution to vertical edges such as where stemwalls and load bearing points meet the horizontal flat work surfaces onthe concrete floor.

The Barrier edging material is also intended to allow smaller sectionsof universal barrier material to be custom fabricated in 6″applications. This would allow for a 12″ or 18″ (6″ widths assembled toany application) insulated area to be constructed out of the universalbarrier edging material in lieu of cutting these widths out of thelarger roll material, reducing waste and promoting ease of use indetailing smaller areas with the universal barrier material.

As can be seen from the above description the combination of componentsprovides a universal barrier system that is designed to insulate thebuilding envelope, providing solutions for large areas, short side widthseams and custom fabrication as well as vertical surfaces that interfacewith horizontal applications as in under the concrete floor and smallarea detail insulation needs. The universal barrier system assembledfrom the components described above provides walls, ceiling and roofareas the same thermal, vapor and moisture benefits as needed in theunder the concrete floor application. Sound attenuation is also providedby the universal barrier system.

FIG. 5 is a flow diagram showing a method of producing a thermal barriercomponent. Universal barrier component is typically constructed on alaminating machine that assembles the 3 typical components (110, 108 and106 of FIG. 2) previously described and disposes them on a roll. Theadhesive (112 of FIG. 1) in the operational area may be disposed on thebase material in this process or optionally in a second stage ofprocessing.

At block 502 a vapor barrier base material is provided to the assemblymachine. At block 504 an outer layer is provided to the assemblymachine, and, at block 506 thermal break is provided to the assemblymachine.

At block 508, the process disposes the thermal break material on thebase material and also disposes an outer layer on top of the thermalbreak. Preparation of a thermal break material that utilizes a uniqueinsulating material that includes air pockets disposed in a polyurethanematerial is detailed in FIG. 6. Alternatively, the lamination processfor disposing the thermal break on the base material may utilize astandard spray or roller lamination process. In one example, a hybridprocess of continuous molding may be utilized to dispose the insulationon the base layer. The process is a hybrid of conventional extrusion andblowing processes that tends to produce a flexible thermal break layer.

In the lamination process 508, the outer layer is typically bonded byconventional methods to the base material at the edges of theoperational area. Thus, the thermal break is sealed against moisture anddirt and is disposed against a firm backing material provided by thebase material. Next, a layer of self-adhesive is disposed at block 510along the lap zone of the base material. And finally, at block 512 theuniversal barrier component is disposed on rolls for shipment and use.

FIG. 6 is a flow diagram showing a method of producing a unique thermalbreak material made from a urethane base that includes microspheres foradded insulation. Hollow glass microspheres (HGMs) may be introduced topolyurethanes (a class of polymer) to increase their insulative values.HGMs typically include an outer rigid glass and inner inert gas, whichresults in some unique properties, such as light weight and low thermalconductivity.

At block 602, a polymer thermal break material is formed into a pliabledough consistency. Polymers such as silicone and urethanes (orequivalently, polyurethanes) may be used. An excellent example that maybe used is MILLATHANE® millable polyurethane rubber from TSE Industries,4370 112th Terrace North, Clearwater, Fla. 33762, USA, or silicone foamor their equivalents. Polyurethanes may be made by reacting adiisocyanate with a polyol and typically a chain extender. Millablepolyurethane may made from both polyester and polyether polyols.Diisocyanates including MDI, TDI, H12MDI and others are commonly used,along with many different chain extenders. Millable urethanes haveproperties comparable to castable or liquid urethanes, which may requiredifferent processing equipment and molding techniques. Millablepolyurethanes can be processed on standard equipment such as internalmixers and rubber mills.

The polymers other than urethane and silicones which may be usedinclude, for example, a rubber and a non rubber polymer. A rubbercopolymer containing a component of cyclic or non-cyclic polyene havingnon-conjugated double bonds (such as butane-1, ethylidene norbomene,etc.), ethylene-propylene rubber, silicone rubber, fluorine rubber,acrylic rubber, polyurethane rubber, polyamide rubber,ethylene-propylene-diene rubber, Natural rubber, polyisobutylene rubber,polyisoprene rubber, chloroprene rubber, butyl rubber,styrene-ethylene-butadiene rubber, styrene-ethylene-butadiene-styrenerubber, styrene-isoprene-propylene-styrene rubber, and chlorosulfonatedpolyethylene rubber or their equivalents.

Non-rubber polymers that may be used other than silicone and urethaneinclude, for example, polyethylene, polypropylene, acrylic polymer,polyvinyl chloride, ethylene-vinyl acetate copolymers, polyvinylacetate, polyamide, polyester, chlorinated polyethylene, styrenepolymers, and epoxy resins or their equivalents.

At block 604, materials or agents are added to the pliable dough todecrease the density by having a higher number of void spaces within thesolid matrix. This novel use (higher void content to matrix) ofmechanical voids (microspheres) greatly increases the thermal insulatingvalue of the foam. As a result, very thin, flexible sheet on roll, downto 1/64″ (or less) thickness can be used to insulate thermal heattransfer.

Hollow glass microspheres that have been chemically sodium depleted canbe used in non-blown urethane foam composites. Possible microspheresthat may be used include, for example, cenospheres (alumino silicatemicrospheres), plastic polymer microspheres, hollow glass microspheres,ceramic microspheres, carbon microspheres, composite and metal—aluminumand silver microspheres or their equivalents.

Insulating materials benefit from high void content. Insulatingmaterials benefit even more with high volume void content microspheres(micro particles) or their equivalents which have diameters typicallyfrom 1 μm to 1000 μm. Hollow microspheres are available in glass,polymer and ceramic.

A hollow microsphere that is non expandable (or an expandable but couldbe calendered without expanding) or its equivalent would be introducedto the plastic dough ball. A hollow microsphere agent to plastic matrixratio of much higher void to matrix would achieve a thermoplastic sheetwith the following improvements and new use for an existing material.

At block 606, the microsphere loaded pliable dough is fed throughtypical calendering mill rollers to form a sheet. In calendering, thematerial is compressed between two rolls that press it out into a film.The film then passes around one or more additional rolls before beingstripped off as a continuous film. The thickness of the film isdetermined by the gap between the compression rollers, in which the gapbetween the calender rolls can be incrementally decreased, and the filmrun through them multiple times to create the desired thickness.

At block 608, the calendering process from block 606 is continued whileperiodically decreasing the space between the rollers. The process iscontinued until the sheet of thermal break material is of the thicknessdesired.

At block 610. The sheet of thermal break material is disposed on rollsto facilitate further handling. Alternatively, the sheet of thermalbreak material may be disposed directly onto the base material at block612.

FIG. 7 is a diagram showing a method of laminating materials to create auniversal barrier component. Shown are rolls containing the optionalouter protective material 110, and one or a multitude of thermal breakmaterials, 108. These rolls have a width, W1, which is narrower than thewidth W2, of the vapor barrier base material 106 in order to provide forthe lap zone (not shown). In one construct, W1 is substantially 48inches and W2 is substantially 54 inches. The resulting lap zone is thensubstantially 6 inches.

The thermal break material rolls may be of urethane or silicone matrixwith high void to matrix content as produced in FIG. 6, for example, orof any other appropriate polymer material and void creating material.The thermal break material 108 is laminated to the polyethylene vaporbarrier base layer 106 with the optional outer protective layer 110, anddisposed on rolls for use. While two layers of thermal break materialare shown, multiple layers of each could, for example, be used toincrease the thermal insulating value dependent on purpose and coderequirement.

By combining differing thermal break materials with differing thermalproperties and void ratios, the resulting material is highly restrictiveof heat flow and provides an improved thermal break. The compoundedproperties of thin walled flexible, highly insulative high void tomatrix foams laminated together is novel to the building industries.

Adhesives may be used to provide a flexible bond between thelaminations. The adhesives that may be used include, for example, arubber or non-rubber adhesive that provides a flexible bond to thelaminations, seams and edges. The flexible bond between layers ofmaterials during the lamination process can be applied by, for example,spray application, roller application or a pressure sensitive adhesive(PSA) disposed on the roll material prior to lamination and activated bythe nip rollers (series of rollers to apply pressure) during thelamination process.

Other adhesives that may be used include, for example, latex (waterbased) adhesives that provide a flexible rubber based bond or theirequivalent. To further improve the insulative properties of theuniversal barrier component, the adhesive could also be modified by theinclusion of microspheres of with a diameter range typically from 1 μmto 1000 μm. The adhesive that may be used, could, for example, includemicrospheres at a higher void to matrix ratio of microspheres to latexand or their equivalents.

Existing adhesives utilizing microspheres have a low void to matrixratio. By using an adhesive with a higher void to matrix of the adhesiveitself, benefits are attained with the flexible bond of adhesion.

These materials may be laminated with nip rollers 702 (a series ofrollers to apply pressure to the multiple sheets). An adhesive 112 maybe applied to the lap zone prior to disposing the universal barriercomponent 100 onto rolls. Alternatively, the adhesive may be applied atanother time. The adhesive may be applied using any appropriateconventional process, and the adhesive may be protected using anon-stick backing or other appropriate material.

FIG. 8 is a perspective view of rigid universal barrier component panels800. In this construct, the operational area of a universal barriercomponent 100 is sandwiched between two rigid, or structural components802 to create a panel that could be used for construction called astructurally insulated panel (SIP or SIP's). If desired, the edges ofthe panel may be sealed with bonding tape 300. Additionally, bondingtape 300 may be used to form a seal between multiple panels used to forma larger construct.

FIG. 9 is a view of a universal barrier vacuum insulated panel system.An example of an additional construct that can be created with universalbarrier system components is a Universal Barrier Vacuum Insulated PanelSystem (VIPS). In this Universal Barrier VIPS, the universal barriersheet material 100 would be used on either side of a core material 902.A good example for this core material would be the web honeycomb cellfrom Hexcel (Hexcel.com) or similar.

These core materials can be made in any shape required for use and theuniversal barrier system conformed around it. Although a rectangularpanel is shown in FIG. 9, any shape, such as curved panels and the likemay be utilized. After enclosing the core material of the VIPS with theoperational area of the universal barrier insulating sheet material 100,and sealing the edges with bonding tape or its equivalent 300, the vapor(gas, air or inert gas such as krypton or its equivalent) within thestructural rigid panel may be vacuumed (evacuated) out from anevacuation port 904 to create a negative pressure environment within thestructure, thereby improving its insulating properties.

Multiple VIPS may be joined together and the joints, or seams sealedwith bonding tape or its equivalent 300. In the VIPS construct, theuniversal barrier component provides a thermal break, a vapor barrier, amoisture barrier, and an acoustic barrier to the vacuum insulated panelsystem while insulating and isolating the core from the outer skin orshell.

If desired, the VIPS may be covered in an outer skin (not shown) toprotect the universal barrier components and or provide another desiredfunction. A good example (like the fabric used on stealth aircraft) ofan exterior skin could be a woven fabric like HexForce® (Hexcel.com) orother composite structure fabric or solid shell or their equivalents. Aninfinite number of shapes, designs and functions open the possibilitiesfor a Universal Barrier VIPS.

While this VIPS is directed at building constructs, it is not limited toconventional residential, commercial and industrial structures.Aerospace industries could benefit from thinner, stronger, betterinsulated materials designed for the future. This VIPS material couldhelp pioneer new shapes for all types of constructs like exoskeletalcomponents or buildings utilizing these materials as deep sea creaturessuch as lobster or crab utilize chitin, with the shapes and strengthsnot currently available in building materials.

This VIPS material could be used in extreme environments like Antarcticaor below sea level. Once these environments are explored, it is logicalto look to extra terrestrial for space exploration and extended livingcolonies or their equivalents. Other more obvious applications of theVIPS for vehicles, permanent and mobile structures, craft for air, sea(above and below the surface) and space all fall into lifesavingequipment.

FIG. 10 is a section view of a concrete slab floor. Common applicationsof a universal barrier system include the concrete industriesspecifications for pouring of slab for flooring. In this application thelarge wide rolls of Universal Barrier component sheet material 100 wouldbe applied to the prepared surface (ground). In this example, the rollsmay be, for example, substantially 54 inches wide with a substantially48 inch operational width and a substantially 6″ lap zone 104. Thissurface (ground) is typically prepared by earth moving equipment,plumbed for utilities and leveled to specified slope on grade with acompacted aggregate 1006. The universal edging material 400 is usedwhere the horizontal material of the first element, the universalbarrier sheet material 100, meets a vertical surface like the stem wall1004 or load bearing structure like a column or pillar. The edgingmaterial 400 is installed with the portion containing only the adhesivein contact with the universal barrier sheet component 100, and theportion containing the thermal break material in contact with thevertical portion of the building's foundation 1004.

This edging material 400 provides a material to address small areas anddetail the vertical perimeter of the larger areas covered by theuniversal barrier sheet component 100, completing the thermal, vapor,moisture and sound attenuation for the concrete floor without loss ofintegrity of any of those functions. Applications for the universalbarrier system include but are not limited to building industries.

FIG. 11 is a plan view of use of a universal barrier system is used witha concrete slab floor prior to installation of the concrete slab. Asshown in FIG. 10, the universal barrier sheet component 100 covers thebulk of the prepared surface, with adjacent sections of the sheetcomponent 100 containing the lap zone 104, which maintains the thermal,vapor, moisture, and sound attenuation throughout the surface. Theuniversal barrier bonding tape 300 is utilized to close seams (as in awidth butt joint) of two sections of Universal Barrier sheet component100 end to end and for seaming custom fabrications.

The universal barrier system edging material 400 is applied to theuniversal barrier sheet component to close the junction between thesheet component 100 and the stem wall 1102. Additionally, the universalbarrier system edging material may be applied to any penetration, suchas those for utilities and other load bearing structures.

FIG. 12 is a section view of a house wall 1200 with a roof and suspendedwood floor utilizing the universal barrier system. Wall applications orceiling/roof applications can be addressed with the universal barriersystem for thermal break, vapor barrier, moisture barrier, and soundattenuation functions. In all applications for the building industry,the universal barrier system provides a complete set of materials forlarge areas, seams, and custom fabrication as well as small areasdetailing the edges of the larger areas while maintaining the integrityof the thermal, vapor, moisture, and sound barrier functions. Althoughonly the universal barrier component for large areas are shown in FIG.12, one skilled in the art will recognize the utility of the bondingtape component and the edging material component in creating andmaintaining the thermal, vapor, moisture, and sound attenuation featuresof the universal barrier system, and provide for establishing andmaintaining the universal barrier properties at doors, windows, andutility penetrations, for example. The entire building envelop can beaddressed with the universal barrier system.

The use of the universal barrier system in a framed wall for providingthermal, vapor, moisture, and sound barrier is shown. A conventionalwall is comprised of a layer of drywall or plaster 1202 on the innersurface of the stud wall 1206. On the exterior of the stud wall is thesheathing 1208 and the siding 1210. Conventional insulation 1204, eitherfoam or batting, is typically installed within the stud wall between thestuds, and a house wrap is typically installed between the sheathing1208 and the siding 1210.

By using the universal barrier system 1212 to replace the house wrap,the conventional house wrap and the conventional insulation may bedispensed with. The universal barrier system includes materials to coverlarge areas, seams, and custom fabrication and small area detailingaround windows, doors, and other penetrations to the building envelop.The universal barrier system 1212 provides a continuous barrier to thebuilding envelop, including at the studs and other framing components

In addition to providing an improved barrier to thermal, vapor,moisture, and sound effects, elimination of the use of conventionalinsulating materials may have health benefits to both constructionworkers and home owners in that the use of toxic materials such asisocyanurates and hazardous materials like fiberglass are eliminated.

The universal barrier system also can be used for framed floors 1222.The flooring system is typically comprised of the flooring 1214, such aswood, tile, or carpet and an underlayment on top of floor sheathing1216. The flooring and sheathing are attached to the floor framing 1218,such as engineered floor joists or dimensional lumber. Typically,conventional insulation 1220 is disposed within the spaces between theframing, leaving the joists uninsulated. Use of the universal barriersystem with a suspended wood floor 1222 provides similar advantages asdescribed above for walls

The construction of ceilings and roofs is similar to that of walls andsuspended floors and the use of the universal barrier system 1226 withfloors and ceilings provides similar advantages to its use in otheraspects of building construction. The universal barrier system can beapplied to either the ceiling joists or bottom chord of a truss system,or to the rafters.

From the previous discussion, it is obvious that the universal barriersystem provides advantages in retrofitting existing construction withimproved energy efficient materials as well as being utilized in newconstruction. The universal barrier system is designed to be easy touse, intuitive, quickly mastered to expert level installation, easilyhandled by one or two users, energy efficient and sustainable.

Those skilled in the art will recognize that although the presentexamples are directed to the use of the Universal Barrier System in thebuilding industries, its use is not limited to solely that applicationand can be used in a multitude of industries.

The lamination process for disposing the thermal break on the vaporbarrier base material may utilize a standard spray or roller laminationprocess. In one example, a hybrid process of continuous molding may beutilized to dispose the insulation on the base layer. The process is ahybrid of conventional extrusion and blowing processes that tends toproduce a flexible thermal break layer.

The universal barrier components tapes and edgings may be configured ina universal barrier system. The universal barrier system may beadvantageously applied to a number of applications and configurations asdescribed below.

A vapor barrier (or equivalently a vapor retarder) may prevent vapors,gases and moisture from entering a structure. Under slab vapor barrierssuch as the universal barrier system may be used on grade constructionbeneath conditioned space or on grade construction covered with amoisture sensitive flooring. In a building without a moisture protectionsystem, the majority of the moisture within the building may originatefrom the building sites' ground water. Ground water may enter a buildingthrough a slab on grade, or below grade walls, via hydrostatic pressure,capillary action or vapor migration. Moisture infiltration through aslab on grade or walls below grade, may cause indoor air quality issuesdue to the proliferation of mold, mildew and fungus. It may also causedamage to the slab and increased building heating costs because of theincreased thermal conductivity of a moist slab. And finally, excessmoisture may cause flooring system failures. Installation of a universalbarrier system may help to remedy these problems.

Preventing moisture infiltration with a universal barrier system may beimportant in preventing flooring failures. In flooring problems, failurecan be evidenced by adhesive failure, warping, discoloration,deterioration and rust stains, and the like. For example, carpetedfloors can wrinkle, wood floors may buckle, and painted floors, such asepoxy coated floors, may bubble. Hydrostatic pressure may be relieved byproper site drainage or by providing a water proofing barrier, such asthe universal barrier system. Capillary action may be minimized bycapillary break layer, or by installing a water proof barrier. Andfinally, vapor pressure may be reduced by installing a vapor barrier.The universal barrier system may function as a capillary break layer, awaterproof barrier and a vapor barrier. Not all materials that are waterproofed are vapor proofed, however, all materials that are vapor proofedare water proofed. An example is fabric having a mechanically expandedlayer of polytetrafluoroethylene, which allows water vapor in the formof perspiration to evaporate, but prevents water from coming through thefabric.

There are a number of industry codes and standards regarding vapor andmoisture barriers. The American Society for Testing Materials (“ASTM”)has issued ASTME 1993-98 Bituminous Vapor Barriers, ASTME 1745-97Plastic Vapor Barriers and ASTME 1643-98 Standard Practice for VaporBarriers. In addition, the American Concrete Institute (“ACI”) hasissued standard ACI 302-1 R-96. In particular the universal barriersystem typically exceeds the Architectural and Building Codes for VaporBarriers, as well as meeting or exceeding the ACI 302-1 vapor barrierspecification for 2006 or its equivalent.

Under slab vapor barrier materials may include low density polyethylene(LDPE) membranes, composite LDPE and asphalt coated craft papermembrane, state of the art LDPE membranes (including polyolefin), crosslaminated LDPE membranes, high density polyethylene (HDTE) membranes,fiber reinforced composite LDPE membranes, and multi-ply bituminousmembranes. These materials have typically been supplied as a singlematerial disposed underneath a slab. Utilization of the universalbarrier system typically outperforms these materials.

When used as a floor, concrete keeps out most liquid water. However,concrete is porous, therefore, some moisture may wick up through theslab and transpire into the air. To mitigate this, a thick crosslaminated, high density polyethylene vapor barrier may be used under aconcrete slab. High density polyethylene vapor barriers are typicallyinstalled on top of a layer of stones that promote drainage, with thehigh density polyethylene vapor barrier being in close contact with theunderside of the concrete.

Building footings are in general, not insulated. Insulated footings canprovide a thermal break to reduce condensation, or mold growth inside abuilding. Insulating the footing tends to keep the concrete on theinside of the structure at the same temperature as the air inside, thus,preventing condensation. Thus, disposing the universal barrier system ona footing may tend to improve the thermal performance of a footing. Inaddition, the universal barrier system may be coupled to a universalbarrier system disposed underneath a floor or slab to form a continuousbarrier.

Structural components such as a window lintel, the edge of a concretefloor slab, or a wood stud in an exterior frame wall can act as thermalbridges conducting heat flow around insulation. A thermal break is aninsulating material intended to prevent structural components (such asconcrete floors, and studs) from acting as thermal bridges. A thermalbreak typically provides a layer of insulation that tends to resist heatflow through a thermal bridge. To provide a thermal break, walls aretypically assembled from the inside out using drywall, studs, insulationin the cavities, Styrofoam, SOB, siding and the like. Thermal breaks maybe spray on insulation which is susceptible to damage by the sun and mayallow the intrusion of termites into the structure. The universalbarrier system advantageously provides a thermal break in addition toits moisture resistance to reduce thermal bridging of heat from a warmerarea to a cooler area.

A universal barrier system may be part of a building envelope. Abuilding envelope can include a universal barrier system to limit waterinfiltration into unwanted areas and allow drainage and drying of wettedbuilding materials. A typical moisture barrier system can include roofcoverings, underlayment, overhangs, gutters, valleys, flashings, housewrap (or felt) and the universal barrier system. Many of thesecomponents may utilize a universal barrier system. A universal barriersystem tends to resist the passage of both air and moisture throughfloors, walls and ceilings. To work properly, the universal barriersystem should be continuously disposed. There should be no tears or gapsnear electrical receptacles, windows and the meetings of walls, ceilingsand floors. The operational area having a self-adhesive edging promotesa continuous universal barrier system by allowing adjoining universalbarrier components to couple to each other. Also, tapes provide a way toseal edges not having a convenient lap zone.

1. A universal barrier system for forming a moisture shield and thermalbreak in a building comprising: a universal barrier tape made frompolyethylene film, up to 12 inches wide to provide typically 6 inches oflap with an adhesive disposed thereon; a plurality of universal barriercomponents supplied in a roll form for use at a job site, each universalbarrier component of the plurality of universal barrier componentssubstantially fifty four inches wide in which the universal barriercomponent includes: a common base component of polyethylene filmsubstantially 6 to 15 mills thick and substantially 54 inches wide andof a length that varies depending upon a desired roll size upon whichthe common base material is disposed, a thermal break having a thicknesssubstantially ranging from 5 mils to 50 mils, and substantially 48inches wide and made from millable polyurethane foam containing voidscreated by microspheres disposed in an operational area substantiallyforty eight inches wide, beginning at an edge of the common basecomponent and leaving a substantially uncovered area substantially 6inches wide along an opposite edge as a lap zone for joining to othermaterials; a protective outer layer of polyethylene film substantially48 inches wide and disposed over the thermal break and has a thicknesssubstantially ranging from 3 mils to 40 mils; and a universal barrieredging including a base material of polyethylene film substantially 6 to15 mills thick, and substantially 12 to 14 inches wide and including: aninsulating material made from millable polyurethane foam containingvoids created by microspheres substantially six to eight inches widedisposed along an edge of the base material and a protective outer layerof polyethylene film disposed over the thermal break and has a thicknesssubstantially ranging from 3 mils to 40 mils; whereby the plurality ofuniversal barrier components and the plurality of universal barrieredging may be assembled with the universal barrier tape to maintain athermal and insulation layer in various shapes in building constructionin which the universal barrier system is disposed.
 2. The universalbarrier system for building construction of claim 1, in which the lapzone further comprises an adhesive disposed thereon.
 3. The universalbarrier system for building construction of claim 1, in which theprotective outer layer covers the thermal break so that it is notexposed.
 4. The universal barrier system for building construction ofclaim 1, in which the microspheres are hollow glass microspheres thathave been chemically sodium depleted and in which the microspheres arebetween 1 μm and 1000 μm.
 5. The universal barrier system for buildingconstruction of claim 1, in which the outer protective layer is highpurity aluminum foil.
 6. The universal barrier system for buildingconstruction of claim 1, in which the millable polyurethane foam isMILLATHANE.
 7. The universal barrier system for building construction ofclaim 1, in which the millable polyurethane foam is made from bothpolyester and polyether polyols.
 8. A method of forming a universalbarrier component comprising: providing a base material formed frompolyethylene film substantially 6 to 15 mills thick and substantially 54inches wide; disposing on the base material a thermal break having athickness substantially ranging from 5 mils to 50 mils, andsubstantially 48 inches wide and made from millable polyurethane foamcontaining voids created by microspheres disposed in an operational areasubstantially forty eight inches wide, beginning at an edge of thecommon base component and leaving a substantially uncovered areasubstantially 6 inches wide along an opposite edge as a lap zone forjoining to other materials; covering the base material with a protectiveouter layer of polyethylene film disposed over the thermal break and hasa thickness substantially ranging from 3 mils to 40 mils, whereby thebase material, the thermal break, and the protective outer layer form alaminated assembly; and winding particular length of the laminatedassembly onto a roll.
 9. The method of forming a universal barriercomponent of claim 8 in which the millable urethane is formed by aprocess comprising: mixing the polyurethane material into a pliabledough; adding void creating agents to the pliable dough; forming thedough into a sheet of a desired thickness; and applying the sheet to thebase material.
 10. The method of forming a universal barrier componentof claim 9 in which the void creating agents are microspheres.
 11. Themethod of forming a universal barrier component of claim 10 in which themicrospheres are hollow glass microspheres that have been chemicallysodium depleted.
 12. The method of forming a universal barrier componentof claim 9 in which the polyurethane material is MILLATHANE.
 13. Themethod of forming a universal barrier component of claim 8 furthercomprising sealing the outer protective layer to the base materialaround a plurality of edges.
 14. The method of forming a universalbarrier component of claim 8 further comprising disposing an adhesive ona lap zone.
 15. The method of forming a universal barrier component ofclaim 8 in which the polyethylene film exceeds the requirements of ASTME-1745 Class A, B and C.
 16. A universal barrier component comprising: abase material substantially fifty four inches wide having a polyethylenebase component with an operational area substantially forty eight incheswide and a lap zone substantially six inches in width in which theoperational area includes a thermal break made from millablepolyurethane foam containing voids created by microspheres disposed onthe base and having the thermal break covered by an outer protectivelayer.
 17. The universal barrier component of claim 16 furthercomprising an adhesive disposed in lap zone.
 18. A universal barriersystem for forming a moisture shield and thermal break in a buildingcomprising: a universal barrier tape made from polyethylene film and anadhesive, up to 12 inches wide to provide typically 6 inches of lap; aplurality of universal barrier components substantially fifty fourinches wide in which the universal barrier component includes a commonbase component upon which a thermal break made from microsphere ladenpolyurethane is disposed in an operational area substantially fortyeight inches wide, and in which the thermal break is made from amicrosphere-laden polyurethane laminated to the common base componentand is encapsulated by an outer protective layer, and a portion of thebase component and the universal barrier component also includes a lapzone of substantially six inches of width, for joining to an adjoininguniversal barrier component at their edges by the universal barriertape; and, a universal barrier edging having an insulating materialsubstantially six to eight inches wide, and a lap zone substantially sixinches wide, and, joined to at least one of the plurality of universalbarrier components by the universal barrier tape.